Explore the stability and efficiency of composite anti-heartburn agents in improving the production process of polyurethane foam

admin 3月 15th, 2025 News

Composite anti-heartburn agent: Improve the stability and efficiency of polyurethane foam production

In the vast starry sky of the chemical industry, there is a magical material – polyurethane foam. It is like a skilled craftsman who uses the clever combination of molecules to shape countless practical products. From car seats to mattresses, from insulation materials to soles, polyurethane foam has become an indispensable part of modern industry with its outstanding performance and wide range of applications. However, behind this seemingly perfect material, there is a headache-inducing problem – heartburn. This phenomenon not only destroys the quality of the foam, but also can lead to instability and inefficiency in the production process. Today, the protagonist we are going to discuss – compound anti-heartburn agent, is the “secret weapon” to solve this problem.

What is heartburn?

To understand the role of complex anti-heartburn agents, you must first understand the essence of heartburn. Simply put, the heartburn phenomenon refers to the problems of hollowing inside the foam, cracking on the surface and even color changes in the foam due to excessive reaction or local overheating during the production process of polyurethane foam. It’s like a pot of boiling porridge suddenly overflowing, not only making people fussy, but also making the whole kitchen mess.

The occurrence of heartburn is mainly related to the following factors:

Reaction rate is too fast: The formation of polyurethane foam requires a chemical reaction between isocyanate and polyol. If the reaction rate is too fast and the heat cannot be dissipated in time, it will lead to excessive local temperature.
Improper catalyst selection: Catalyst is the key to controlling the reaction rate. If the amount of catalyst is used too much or the type is not suitable, the reaction may be accelerated and heartburn may occur.
Raw material quality is unstable: Raw materials may contain impurities or moisture, which will release additional heat during the reaction, further aggravate the heartburn.

The appearance of compound anti-heartburn agent

To solve these problems, scientists have developed a composite anti-heartburn agent. This is an additive composed of a variety of functional substances, which can play a stable role in the production process of polyurethane foam, thereby effectively inhibiting the occurrence of heartburn. It is like a calm commander who directs the otherwise disorderly chemical reaction to a smooth and orderly track.

The working principle of composite anti-heartburn agent

The core functions of compound anti-heartburn agents can be summarized as follows:

Regulate the reaction rate: By interacting with the catalyst, the intensity of the initial reaction is reduced, making the entire reaction process more stable.
Dispersing heat: Certain components can help absorb or conduct excess heat and avoid local overheating.
Optimize foam structure: Improve the pore distribution of foam and reduce defects caused by heartburn.

Next, we will explore in-depth the specific composition, application effect and impact on production efficiency of composite anti-heartburn agents.

Composition and classification of composite anti-heartburn agents

Composite anti-heartburn agents are not single chemical substances, but composite materials made of a mixture of multiple functional components in a certain proportion. Depending on its mechanism of action, it can be divided into the following categories:

1. Thermal stabilizer

The main function of the heat stabilizer is to absorb or conduct excess heat generated during the reaction, thereby preventing local overheating. Common heat stabilizers include:

Magnesium oxide (MgO): It has good heat absorption properties and can effectively reduce the system temperature.
Aluminum hydroxide (Al(OH)?): It can not only absorb heat, but also decompose and generate water vapor at high temperatures, which can play a cooling role.

Ingredients	Functional Features	Recommended addition (%)
Magnesium oxide	Absorb heat and reduce local temperature	0.5-1.0
Aluminum hydroxide	Decompose and produce water vapor, taking away heat	1.0-2.0

2. Reaction regulator

The reaction regulator regulates the reaction rate by interacting with the catalyst to make it more stable. Such ingredients usually include:

Phosphate compounds: Such as triphenyl phosphate (TPP), it can slow down the reaction rate of isocyanate and polyol.
Silane coupling agent: Indirectly affects the reaction process by changing the active site of the raw material molecule.

Ingredients	Functional Features	Recommended addition (%)
Triphenylphosphate	Slow downReaction rate, improve system stability	0.2-0.5
Silane coupling agent	Adjust the molecular activity of raw materials and optimize reaction conditions	0.1-0.3

3. Foam Modifier

The function of foam modifier is to optimize the microstructure of the foam and reduce defects caused by heartburn. For example:

Silicon emulsion: It can significantly improve the pore distribution of foam and enhance mechanical properties.
Polyetheramines: Helps to form a more uniform foam structure.

Ingredients	Functional Features	Recommended addition (%)
Silicon emulsion	Improve foam pore distribution and reduce defects	0.5-1.5
Polyetheramine compounds	Enhance foam uniformity and improve physical performance	0.3-0.8

4. Other auxiliary ingredients

In order to further improve the effect of the composite anti-heartburn agent, some auxiliary ingredients can also be added, such as antioxidants, moisture-proofing agents, etc. Although these ingredients are used in small amounts, they play an important role in improving overall performance.

Ingredients	Functional Features	Recommended addition (%)
Antioxidants	Prevent raw materials from oxidation and prolong storage time	0.05-0.1
Moisture-proofing agent	The effect of reducing moisture on reaction	0.1-0.3

The application effect of compound anti-heartburn agent

The introduction of composite anti-heartburn agents not only solves the quality problems caused by heartburn, but also significantly improves the stability and efficiency of polyurethane foam production. The following is an analysis of its specific application effects:

1. Improve product quality

Suppressing heartburn, composite anti-heartburn agent can significantly improve the appearance and physical properties of the foam. Experimental data show that after using the composite anti-heartburn agent, the density deviation of the foam was reduced by 30%, the pore distribution was more uniform, and the mechanical strength was increased by more than 20%.

Test items	Anti-living agent not used	Use anti-living agent	Elevation (%)
Density deviation	±10%	±7%	30
Pore homogeneity	60%	85%	–
Mechanical Strength	15 MPa	18 MPa	20

2. Enhance production stability

The use of composite anti-centrifuge agents makes the reaction process more stable and controllable, reducing equipment failure and downtime caused by centering. According to statistics from a large polyurethane manufacturer, after the introduction of composite anti-heartburn agent, the failure rate of the production line decreased by 40% and the production cycle was shortened by 15%.

Test items	Anti-living agent not used	Use anti-living agent	Elevation (%)
Fault Rate	5%	3%	40
Production cycle	3 hours/batch	2.5 hours/batch	15

3. Improve economic benefits

In addition to direct technical improvements, the use of composite anti-living agents also brings considerable economic benefits. Due to the improvement of product quality and production efficiency, the overall cost of the enterprise has been reduced by about 10%. In addition, due to the decrease in the waste rate, the utilization rate of raw materials has also been significantly improved.

Test items	Anti-living agent not used	Use anti-living agent	Elevation (%)
Comprehensive Cost	$100/ton	$90/ton	10
Scrap rate	8%	3%	62.5

Progress in domestic and foreign research

The research and development and application of composite anti-heartburn agents have always been the focus of attention of the polyurethane industry. In recent years, domestic and foreign scholars have conducted a lot of research on its composition, performance optimization and practical applications.

Domestic research status

my country’s research in the field of compound anti-heartburn agents started late, but developed rapidly. Universities and research institutions represented by Tsinghua University and Zhejiang University have achieved remarkable results in this field. For example, a study from the Department of Chemical Engineering of Tsinghua University showed that by optimizing the formulation of composite anti-heartburn agents, the pore uniformity of foam can be increased to more than 90%. At the same time, domestic enterprises are also actively developing new composite anti-heartburn agents, striving to achieve import substitution.

Foreign research trends

In contrast, European and American countries are more mature in the research on compound anti-living agents. DuPont has developed a composite anti-heartburn agent based on nanotechnology, which has far surpassed traditional products. Germany’s BASF focuses on the direction of green chemistry and has launched a series of environmentally friendly composite anti-heartburn agents, which meet increasingly stringent international environmental standards.

Research Institutions/Enterprise	Main research results	Features
Tsinghua University	New Complex Anti-Heartburizing Formula	Improve pore uniformity to more than 90%
DuPont	Nanoscale composite anti-living agent	Excellent performance, wide application scope
BASF	Environmentally friendly composite anti-living agent	Complied with international environmental standards

Conclusion: Future Outlook

The importance of composite anti-heartburn agents as key additives in the production of polyurethane foams is self-evident. With the advancement of science and technology and changes in market demand, the research and development of composite anti-heartburn agents will also usher in new opportunities and challenges. Future directions may include:

Intelligent regulation: By introducing intelligent material technology, real-time monitoring and dynamic adjustment of the reaction process can be achieved.
Green and environmentally friendly: Develop more composite anti-heartburn agents that meet environmental protection requirements to promote the sustainable development of the industry.
Multi-function integration: Integrate multiple functions into a single product, simplify production processes and reduce costs.

In short, the development of composite anti-heartburn agents not only concerns the quality and efficiency of polyurethane foam, but also the technological innovation and industrial upgrading of the entire chemical industry. Let us look forward to more exciting performances in this field together!